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Unread 09-26-2012, 01:08 AM   #1
Not Yet Wild
 
Join Date: Nov 2011
Posts: 29
Default Bad boy buggy help!! (solenoid) maybe!

Long story short a friend of mines dad dropped off his bad boy buggy to have me look at, apparently he thinks I know what I am talking about since I brought 1 golf cart to life after using everyone's help on this site. this bad boy buggy is an 06 highlander 4x4 he bought it new and has probably only ran it about 10 times, other than that it has just been sitting at his game ranch. The cart is muddy and has some corroted cables, I have checked all batteries individually and ran a full load with my volt meter everything checks out fine.
This is a 48v system with 8-6v batteries which read:
B1-6.61, B2-6.64 B3-6.61 B4-6.62 B5-6.62 B6-6.57 B7-6.60 B8-6.59
and reading a full load of 52.1 this is all after a full charge.
When I turn the cart on I can here all the clicking noises from the solenoids, I think there is either 2-4 solenoids on this thing. When I give it gas the solenoid clicks again and jumps just a little as if it is trying to go, this happens in forward and reverse. After about 15 seconds of this it just stops, if I turn the key off then back on it does the exact same thing. At first I thought maybe the cables needed to be cleaned or replaced but I disregard that after getting full volt readings. I wanted to eleminate the solenoids after hearing them click but have read that they can still be bad even if they click. I know there isnt too much info on bbb on this site but from looking at it; it seems to be the same set up at most carts. Question is does anyone know how many solenoids are on these things and if so is there anyway I can't test them. any starting point would be much appreciated before sinking a bunch of money into it, thanks in advance.
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Unread 09-26-2012, 07:30 AM   #2
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Join Date: Oct 2008
Location: Ga
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Default Re: Bad boy buggy help!! (solenoid) maybe!

Champ,

I didn't know BBB had more than one solenoid? 1 for the front motor? 1 for the rear motor? So are the batts 6 yrs old? Is there any kind of dianostic mode you can check on a BBB? Did you get everything cleaned up?
Steve
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Unread 09-26-2012, 07:41 AM   #3
nimda
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Default Re: Bad boy buggy help!! (solenoid) maybe!

I believe thats a BB1 model, if so I think its navitas powered. (green controller) Should be a Reversing contactor on the right hand side and a 2wd/4wd contactor somewhere. The reversing contactor is open to the elements....things can get inside the contact area. You may want to check theres not mud or a stick or something in there....you never know.

Heres the wiring schematics from Badboy (hand drawn )

www.buggiesgonewild.com/series-big-cables.pdf
www.buggiesgonewild.com/series-small-wires.pdf

Theres not much info out there for badoy....any info you gleam from your situation would help people in the future if you post what you learn.
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Unread 09-26-2012, 07:45 AM   #4
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Default Re: Bad boy buggy help!! (solenoid) maybe!

Quote:
Originally Posted by caokgafamily View Post
Champ,

I didn't know BBB had more than one solenoid? 1 for the front motor? 1 for the rear motor? So are the batts 6 yrs old? Is there any kind of dianostic mode you can check on a BBB? Did you get everything cleaned up?
Steve


On the SEPEX models there is one for front and one for rear. SEPEX (2 SEVCON controllers, one for each motor) Which, if memory serves me correctly is 07 up.
06 down if I remember correctly is SERIES (single Navitas controller) and has a reversing contactor and a 2wd/4wd contactor.
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Unread 09-26-2012, 11:46 PM   #5
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Default Re: Bad boy buggy help!! (solenoid) maybe!

Thanks for the reply's, Roady you are correct there is only 1 solenoid. Today I removed and cleaned all cables put everything back together and am still having the same problem. Also I jacked up the cart pressed the gas and it still just clicks and stutters a little. Next it tried to jump the solenoid but nothing happend as well. After reading through the wiring drawing that roady provided I noticed that all the clicking is coming from the contactors, I have 2 contactors on passenger side and 1 on the driver side, not too sure which is which on them but they definately seem to be the problem. Is there any way to test them with a volt meter or a special way to clean them.
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